Attachment 2 ModI-LargePulper_FabInsp.docx

DOCX document 57 KB Posted Jun 29, 2023

Attached to: NSWCPD Pulper and Shredder Processing Equipment Federal contract opportunity
Solicitation number: N64498-23-RFPREQ-PD-33-0175
Issued by: Department of the Navy Naval Sea Systems Command

About this file

Written by GovTribe AI · Dec 21, 2023

This document outlines inspection procedures and test records for a large pulper processing equipment. The procedures cover fabrication inspection, assembly inspection, general examination, static leak testing, run testing, and inspection of the PLC-based controller. Critical dimensions, components, and characteristics are verified against engineering drawings. Tests include filling the pulper with water for 30 minutes to check for leaks, running the pulper continuously for 30 minutes while observing for abnormal conditions, and simulating various alarm conditions to verify controller performance. Electrical verifications include checking voltages, currents, and controller responses to proximity switches, differential pressure switches, overcurrents, and other inputs. The document provides detailed pass/fail criteria and sign-off requirements for inspectors and vendors at each stage to ensure the pulper and controller meet specifications before acceptance.

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Other files for this federal contract opportunity

Other files attached to NSWCPD Pulper and Shredder Processing Equipment, newest first.
File	Type	Posted
Attachment 6 ModI-LargePulperEE_FabInsp.docx	DOCX document	Jun 29, 2023
Attachment 5 ModI-PShredder_FabInsp.docx	DOCX document	Jun 29, 2023
Attachment 7 SmallPulperEE_FabInsp.docx	DOCX document	Jun 29, 2023
Attachment 4 SmallPulper_FabInsp.docx	DOCX document	Jun 29, 2023
Attachment 3 ModI-MGShredder_FabInsp.docx	DOCX document	Jun 29, 2023
Attachment 1 - Drawings of Record.xlsx	XLSX spreadsheet	Jun 29, 2023
DRAFT SOW_PULP-SHRED HARDWARE.doc	DOC document	Jun 29, 2023

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ATTACHMENT B – TESTING

B1- Large Pulper

Large Pulper Fabrication Inspection Procedures and Record, LP001

Revision: - Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Large Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ ____________________/_______________

Vendor Approval: _________________________ ____________________/_______________

1.0 Introduction

1.1 The purpose of this inspection is to verify that critical dimensions of the large pulper have been met during fabrication.

2.0 Equipment.

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the equipment shall be one order of magnitude finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required includes: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment.

3.1	Nomenclature: 1.500-6 UNC-2A Left Hand Thread Ring
	Purpose: For measuring threads on the impeller drive shaft

3.2	Nomenclature: 1.500-6 UNC-2B Left Hand Thread Plug
	Purpose: For measuring threads on the impeller disc

4.0 Services: None.

Large Pulper Fabrication Inspection Procedures and Record, LP001

Results

Inspection Step Number

Inspection Step Description

Sat

Unsat

Initials/

Date

— Direct measurement or record review methods may be used —

Inspector Record, Revision of Drawing Used Initials

Reference — Dwg. No. 593-8729130 (Top Level Assembly) Rev _______ _______ Dwg. No. 593-6960302 (Rail Weldment) Rev _______ _______ Dwg. No. 593-6960311 (Slurry Chamber) Rev _______ _______ Dwg. No. 593-6960318 (Impeller Assembly) Rev _______ _______ Dwg. No. 593-6960319 (Security Ring) Rev _______ _______ Dwg. No. 593-6960331 (Bearing Housing & Details) Rev ______ ______ Dwg. No. 593-6960332 (Impeller Drive Shaft) Rev _______ _______ Dwg. No. 593-6960333 (Impeller Disc) Rev _______ _______ Dwg. No. 593-6960338 (Junk Box Basket) Rev _______ _______ Dwg. No. 593-6960342 (Cutting Ear) Rev _______ _______ Dwg. No. 593-6960347 (Orifice Plates and Screen) Rev ______ ________ Dwg. No. 593-6960500 (Control Enclosure) Rev _______ _______

Verify the following from the Top Level Assembly (Dwg No. 593-6960300)

A) Brazing is in accordance with Note 1.6 B) All brazed piping has been pressure tested in accordance with Note 1.6.1

Verify the size and location of the 4X 1.074/1.062 diameter holes are as shown on the rail drawing (Dwg. No. 593-6960302)

Verify the following characteristic of the slurry chamber: 18.750/18.746 diameter

Verify that the impeller assembly has been balanced per Note 4 of Dwg. No. 593-6960318.

Verify that the security ring has been welded in accordance with Dwg. No. 593-6960319 Notes 3 (weld qualifications) and 4 (weld procedure and examination) .

Verify the following characteristics of the security ring are within tolerance (Dwg. No. 593-6960319, Detail 6-A).

A) 18.762/18.754 diameter B) 5 X R 9.78/9.75 to corner of Pc. 5

Verify that the following characteristics of the bearing housing (Dwg. No. 593-6960331 piece 1, Sections 5-D, and 7-D) are within tolerance:

A) 6.3015/6.2995 diameter

B) 5.500 Depth 2 X

C) 3.251/3.250 diameter

D) 8.686/8.684 diameter

Verify that the following characteristics of the end bell (Dwg. No. 593-6960331 piece 2, Detail 14-D) are within tolerance:

A) 3.251/3.250 diameter

B) 0.120 depth

C) Surface B

D) 6.283 diameter

Verify that the following characteristics of the interior seal plate (Dwg. No. 593-6960331 piece 3, Section 10-A) are within tolerance:

A) 8.682/8.680 diameter

B) 3.126/3.124 diameter

Verify that the following characteristics of the impeller drive shaft (Dwg. No. 593-6960332, Details 5-B and 4-A) are within tolerance:

A) 2.000/1.998 diameter

B) 2 X 2.500/2.498 diameter 32 surface

C) 2 X 2.9540/2.9533 diameter

D) 2.250/2.248 diameter 63 surface

E) 1.554/1.550 diameter 32 surface

F) 2.262 dimension

G) 5.610 dimension

H) 1.500-6 UNC-2A left hand threads

Verify that the following characteristics of the impeller disc (Dwg. No. 593-6960333) are within tolerance:

A) 1.500-6 UNC-2B left hand threads

B) 1.568/1.565 diameter

C) 3.125/3.094 diameter

D) 3.469/3.438 diameter

E) 2 X 7.536/7.526 diameter

F) Cutting ear mounting hole size and location per Detail 6-C

G) 18.705/18.700 diameter

Verify the length of the Junk Box Basket (Dwg. No. 593-6960338) is 17.50/17.38.

Verify the following characteristics of the cutting ears (Dwg. No. 6960342) are within tolerance:

A) 4.270 dimension B) 0.375 dimension C) 77.5 degree angle D) Cutting ear mounting hole size and locations E) Impeller blade mounting hole size and locations F) 65 degree angle

Verify the orifice plate diameters (Dwg. No. 593-6960347).

A) 1.000 diameter, piece 1, do not break corners B) 0.875 diameter, piece 2, do not break corners

Verify that the size (4 x 0.541/0.531 diameter) and location of the electrical control enclosure mounting holes are in accordance with Dwg. No. 593-6960500, Sheet 5, Detail 39-C.

Test Complete

Large Pulper Assembly Inspection Procedures and Record, LP002

Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Large Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ ____________________/______________

Vendor Approval: _________________________ ____________________/______________

1.0 Introduction

1.1 The purpose of this inspection is to verify that critical components of the large pulper have been properly assembled.

2.0 Equipment.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment: None

4.0 Services: None.

Large Pulper Assembly Inspection Procedures and Record, LP002

Inspection Step Number

Inspection Step Description

Results

Initials/

Sat

Unsat

— Direct measurement or record review methods may be used —

Inspector Record, Reference — Dwg. No. 593-6960300 (Top Level Assembly) Rev _______ ______ Dwg. No. 593-6960320 (Lower Shell Assembly) Rev _______ ______ Dwg. No. 593-6960330 (Impeller Drive Assembly)Rev _______ ______ Dwg. No. 593-6960334 (Junk Box Assembly) Rev _______ ______

Verify that the impeller drive assembly has been assembled in accordance with Dwg. No. 593-6960330. Also verify the following characteristic AFTER assembly is complete:

A) Shaft torque is less than 7 ft-lbs

Verify that the lower shell has been assembled and adjusted in accordance with Dwg. No. 593-6960320.

Verify that the access door opens fully to a HARD STOP between the door bar weldment (Dwg. No. 593-6960320 piece 2) and the lower shell weldment (Dwg. No. 593-6960320 piece 1).

Verify that the junk box assembly has been assembled and adjusted in accordance with Dwg. No. 593-6960334.

Verify that the stationary seat, bellows seal, and O-ring (Dwg. No. 593-6960300 pieces 56, 55 and 43) are properly installed per Notes 2.2.2 and 2.2.3. Verify that anti-seize compound is applied to the shaft thread per Note 2.2.3.

Verify that the impeller assembly (Dwg. No. 593-6960300, Pc. 11) has been installed in accordance with Note 2.2.4.

Verify that the sheaves (Dwg. No. 593-6960300 pieces 46 and 47) are properly aligned per Notes 2.3.1 and 2.3.2.

Verify that the drive belt (Dwg. No. 593-6960300, Pc. 48) has been installed per View 34-A.

Verify that the tensioner spring (Dwg. No. 593-6960300 piece 20) is installed and adjusted to 1.09 inch height.

Verify that the overflow screen and orifice plates (Dwg. No. 593-6960300 pieces 116, 117, and 118) are installed.

Verify that the proximity switches (Dwg. No. 593-6960300 piece 161) are properly installed and tested per Note 3.6.

Verify that the junk box gasket (Dwg. No. 593-6960300 piece 13) has been trimmed on the inside per View 38-A.

Inspection Complete

Large Pulper General Examination Procedures and Record, LP003

Revision Date: 12/5/96 Security Classification: UNCLASSIFIED

Large Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ ________________________/___________

Vendor Approval: _________________________ ________________________/___________

1.0 Introduction

1.1 The purpose of this examination is to verify that the large pulper components are properly assembled and adjusted.

2.0 Equipment.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment: None.

4.0 Services: None.

Large Pulper General Examination Procedures and Record, LP003

Inspection Step Number

Inspection Step Description

Results

Initials/

Sat

Unsat

Inspector Record, Reference – Dwg. No. 593-6960300 (Top Level Assembly) Rev _______ _______ Dwg. No. 593-6960320 (Lower Shell Assembly) Rev _______ _______ Dwg. No. 593-6960334 (Junkbox Assembly) Rev _______ _______ Dwg. No. 593-6960500 (Control Enclosure) Rev _______ _______ Dwg. No. 593-6960503 (Local Status Indicator) Rev _______ _______

DANGER. Ensure that no electrical connections have been made to the drive motor.

Verify that the impeller (Dwg. No. 593-6960300 piece 11) and drive components rotate freely by hand.

Verify that all belt guards, danger labels, caution labels and the rotation label are installed (Dwg. No. 593-6960300 pieces 23, 24, 25, 49, 50, 141 and 168)

Cycle the access and junk box doors and latch assemblies (Dwg. No. 593-6960320 and 593-6960334) 5 times and verify smooth operation.

Verify that a service loop is provided in cable W104 per Dwg. No. 593-6960300, Zone 54-D.

Verify that all cables are cut to the proper length and secured to the pulper in accordance with Dwg. No. 593-6960300.

Verify that all heat discoloration has been removed per Note 1.5.1 of Dwg. No. 593-6960300.

Verify workmanship per Dwg. No. 593-6960300, Notes 1.7 and 1.8.

Verify that the following nameplates are properly completed, are legible and are attached:

A) Pulper (Dwg. No. 593-6960300, Pc. 26)

B) Control Enclosure (Dwg. No. 593-6960500, Pc. 61)

C) Local Status Indicator (Dwg. No. 593-6960503, Pc. 2)

Verify that the drive belt and sheave surfaces are clean, dry, and free from grease, dirt, or other debris or damage.

Examination Complete

Large Pulper Static Leak Test Procedures and Record, LP004

Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Large Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ ________________________/___________

Vendor Approval: _________________________ ________________________/___________

1.0 Introduction

1.1 The purpose of this test is to verify that the large pulper does not leak when subjected to a static head of water.

1.2 The large pulper shall be fully assembled.

2.0 Equipment.

2.1 Calibrated measuring equipment is required to verify drawing dimensions. The precision of the equipment shall be one order of magnitude finer than the characteristic to be measured. The equipment calibration shall be current. The equipment required include: gage blocks, scales, calipers, micrometers, surface plate with height gage, angle gage, adjustable protractor, depth micrometers, inside micrometers, and thread gages; a coordinate measurement machine may be used in lieu of many of the above.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment.

3.1	Nomenclature: 37 degree Flare Capnut, -20 Size, 1 5/8-12 Thread,
	(SAE 20-070112 or suitable alternative)
	Use of the Test Equipment: Seal the impeller flush fitting
	Material: Stainless Steel
	Class: 150 lbs

3.2	Nomenclature: 2.00 NPS ANSI blind flange and gasket (or suitable alternative)
	Use of the Test Equipment: Seal the junk box and upper shell supply pipe
	Material: Bronze
	Class: 150 lbs

3.3	Nomenclature: 3.00 NPS ANSI blind flange and gasket (or suitable alternative)
	Use of the Test Equipment: Seal the slurry discharge pipe
	Material: Bronze
	Class: 150 lbs

4.0 Services

4.1 Fresh Water (to fill the pulper, no flow and pressure requirements are specified)

4.2 Gravity Drain

Large Pulper Static Leak Test, LP004

Inspection

Number

Inspection Step Description

Results

Initials/

Sat

Unsat

Inspector Record, Reference — Dwg. No. 593-6960300 (Top Level Assembly) Rev _______ _______

DANGER. Ensure that no electrical connections have been made to the drive motor.

Inspect the pulper chamber and junk box for any loose hardware or miscellaneous debris.

Close and secure the access door, junk box door, and drain valve.

Verify that the blind flange (Dwg. No. 593-6960300 piece 123) is in place on the junk box.

Secure capnut and blind flanges to the following:

A) -20, 37 degree flare capnut to the impeller flush fitting.

B) 2.00 NPS ANSI to the junk box and upper shell supply pipe C) 3.00 NPS ANSI to the slurry discharge pipe

Fill the pulper chamber with fresh water to a level approximately 2 inches below the level that will overflow the feed tray lip (Dwg. No. 593-6960300 piece 5).

If signs of surface sweating occur, wipe the external surface of the pulper dry before proceeding with the test.

Allow the water to set in the pulper for 30 minutes and observe all external pulper surfaces for signs of leakage. Zero leakage is permitted. If any leaks are present, stop the test, resolve the leak and reconduct the test.

Upon successful completion of the static leak test, drain the pulper.

Wipe down the interior of the pulper. The interior surfaces may be damp to the touch. There should be no puddled water.

Test Complete

Large Pulper Run Test Procedures and Record, LP005

Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Large Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ ________________________/_________

Vendor Approval: _________________________ ________________________/_________

1.0 Introduction

1.1 The purpose of this test is to verify that the large pulper operates smoothly and that no leaks occur while running.

1.2 The large pulper shall be fully assembled.

2.0 Equipment.

2.2 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.3 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment.

3.1	Nomenclature: Adapter 37 degree Flare, -20 Size, 1 5/8-12 Thread
	(or suitable alternative)
	Use of the Test Equipment: Connect supply water to the impeller flush hose
	Material: Stainless Steel
	Class: 150 lbs

3.2	Nomenclature: 2.00 NPS ANSI blind flange and gasket (or suitable alternative)
	Use of the Test Equipment: Seal the junk box and upper shell supply pipe
	Material: Bronze
	Class: 150 lbs

3.3	Nomenclature: 3.00 NPS ANSI flange and adapter (or suitable alternative)
	Use of the Test Equipment: Connect slurry discharge pipe to gravity drain
	Material: Bronze
	Class: 150 lbs

3.4	Nomenclature: #10 AWG single conductor cable
	Use of the Test Equipment: Grounding
	Range: Length as required for ground.

3.6	Nomenclature: #10 AWG 4-conductor cable
	Use of the Test Equipment: Power Leads
	Range: Length as required.

4.0 Services

4.1 Fresh Water, 15 - 20 gpm at 8 - 10 psig for the large pulper

4.2 Gravity Drain

4.3 440 Vac, 3 Phase, 60 Hz, 30 Amp supply (minimum) with circuit breaker element of 30 Amp

Large Pulper Run Test Procedures and Record, LP005

Inspection

Number Inspection Step Description Results

Initials/

Sat

Unsat

DANGER: Electrical safety precautions shall be carefully followed since test personnel are exposed to 440 Vac that is required to operate the drive motor.

Secure the pulper to prevent movement during the run test.

Inspect the pulper chamber and junk box for any loose hardware or miscellaneous debris.

Verify that the impeller assembly rotates freely by hand.

Close and secure the access door, junk box door, and drain valve.

Verify that the blind flange (Dwg. No. 593-6960300 piece 123) is in place on the junk box.

Connect the blind flange to the 2.00 supply pipe (Dwg. No. 593-6960300 piece 80).

Place the 30A circuit breaker at the 440 Vac power panel in the open position and tag it out.

Ground the drive motor frame to the electrical ground of the 440 Vac power source using a single-conductor #10 AWG cable.

Connect the 440 Vac load side of the 30A circuit breaker to the drive motor using a #10 AWG 4-conductor cable, length as required.

Connect a drain line to the 3.00 slurry discharge pipe (Dwg. No. 593-6960300 piece 119) to drain the pulper at the same rate (15 - 20 gpm) as the supply.

Connect water supply (15 - 20 gpm at 8 - 10 psig) to the impeller flush fitting (Dwg. No. 593-6960300 piece 115) and fill the pulper to a level 2 to 4 inches above the uppermost edge of the slurry chamber (motor end).

Remove the tagout and close the 30A circuit breaker for just long enough to initiate rotation. Carefully observe impeller rotation to ensure it is rotating clockwise. (Looking down through the upper shell curtain). If rotation is counter-clockwise open the 30A circuit breaker (tagout) and switch two of the 3-phase leads and retest for proper rotation.

CAUTION: Never run the pulper without 15 - 20 gpm of water flowing into the impeller flush hose.

Turn on water supply and close the 30A circuit breaker. The drive motor should start and achieve full speed within about 2 seconds.

Run the pulper continuously for 30 minutes. Observe the pulper during startup, run and shutdown.

A) Observe the height of the water vortex in the pulper after the motor has achieved full speed. Note that the water vortex will appear higher than when the pulper was initially filled. It may be necessary to adjust the water flow being discharged from the pulper during the test to maintain a constant water level.

B) Observe pulper connections for any leaks. If any leaks are present, stop the test, resolve the leak, and reconduct test.

C) Monitor the operation of the pulper for any abnormal condition. Abnormal conditions include: excessive vibration, unusual noises, water leaks, and signs of excessive heating. If any abnormal conditions are noted resolve the condition and reconduct the test.

D) Verify that no mechanical seal leakage has occurred by checking beneath pulper for water. If the mechanical seal shows signs of leakage, stop the test, resolve the leak, and reconduct the test.

After 30 minutes of continuous operation, open the 30A circuit breaker at the 440 Vac power panel and tag it out. Disconnect the 440 Vac power cable and ground cable from the drive motor and the 30A circuit breaker.

Drain the contents of the pulper including the junk box and perform a general examination of the interior and exterior of the pulper. Inspect for any abnormal conditions such as loose hardware or debris, drive belt loosening, and for water or grease leakage from the impeller drive assembly.

Wipe down the interior of the pulper. The interior surfaces may be damp to the touch. There should be no puddled water.

Test Complete

Large Pulper Inspection Procedures and Record for the PLC Based Controller, LP006

Revision Date: 1/4/97 Security Classification: UNCLASSIFIED

Large Pulper Serial Number: ___________

Inspection Date: _______________

Name (Printed) Signature/Date

Inspection Person: _________________________ _____________________/________

Vendor Approval: _________________________ _____________________/________

1.0 Introduction

1.1 The purposed of this inspection is to verify the electrical performance of the controller.

2.0 Equipment.

2.1 Common tools and equipment (wrenches, screw drivers, fasteners, scales, micrometers, etc. ) required to accomplish this procedure ARE NOT identified.

2.2 Contractor-provided jigs, fixtures, and test apparatus ARE NOT identified.

3.0 Special Tools and Equipment.

3.1	Nomenclature: #10 AWG single conductor cable
	Use of the Test Equipment: Grounding
	Range: Length as required for ground.

3.2	Nomenclature: #10 AWG 4-conductor cable
	Use of the Test Equipment: Power Leads
	Range: Length as required.

3.3	Nomenclature: Multimeter
	Use of the Test Equipment: Continuity checks
	Accuracy: +/- 2% of scale, Calibration within 12 months
	Range: Low Ohms and 500 Vac
3.4	Nomenclature: Jumper
	Quantity: 3
	Use of the Test Equipment: #16 AWG Wire Minimum

3.5	Nomenclature: Single-phase Variac capable of supplying 10 Amps
	Use of the Test Equipment: Simulate current through the C-T

3.6	Nomenclature: Clamp on Ammeter
	Use of the Test Equipment: Current simulation of current transducer verification
	and alarms checkout
	Accuracy: +/- 2% of scale, Calibration within 12 months
	Range: 0 - 10 Amps

4.0 Services

4.1 440 Vac, 3 Phase, 60 Hz, 30 Amp supply (minimum) with circuit breaker element of 30 Amp

4.2 100 Vac, 60 Hz, single-phase, 15 Amp supply

Large Pulper Inspection Procedures and Record for the PLC Based Controller, LP006

Test Step Number

Test Step Description

Results

Initials/

Sat

Unsat

Inspector Record, Reference – Dwgs. No. 593-6960500 Rev ________ ________ Dwgs. No. 593-6960501 Rev ________ ________ Dwgs. No. 593-6960879 Rev ________ ________ Dwgs. No. 593-6960300 Rev ________ ________ Dwgs. No. 593-6960503 Rev ________ ________ Dwgs. No. 593-6960504 Rev ________ ________

Assumptions

- Before initiating any testing, verify that point-to-point wiring checks have been made to verify correct wiring.

- Pulper is not attached, therefore, differential pressure switch, conductivity switches, and remote E-stop actions are simulated at terminal board TB1 and TB3.

- The correct Programmable Read Only Memory (PROM) version is installed in the Programmable Logic Controller (PLC) and Display Unit (DU1).

- The electrical enclosure (Dwg. No. 593-6960500, sheet 3) door is open for access to electrical components and observation of PLC indicators. The retaining screws (Dwg. No. 593-6960500, sheet 3, pc 114) on the display unit cover are loose so that the function keys on the display unit can be operated. The local status indicator is installed at terminal board TB1 (Dwg. No. 593-6960504).

DANGER: Electrical safety precautions shall be observed since the test person is exposed to both 440 Vac and 110 Vac.

If any of the following verifications cannot be made as described, troubleshoot as required to isolate the cause and/or failed component.

PLC Configuration Record the following information

A) PLC Baseplate Part and Revision Number

B) System PROM Serial Number Installed on the PLC Baseplate _______

C) Serial Number of the Electrical Enclosure __________

Set overload relay for automatic reset and 25A.

Check fuses – Continuity check with ohmmeter:

Connect local status indicator enclosure via cable W102 (Dwg. No.593-6960300 and 593-6960504).

Connect proximity switches on TB3 in local status indicator (Dwg. No. 593-6960503) and place metal flag on both switches:

TB3-5 to PX1-1 (Brown Lead) TB3-6 to PX1-2 (Blue Lead) TB3-6 to PX2-1 (Brown Lead) TB3-7 to PX2-2 (Blue Lead)

Connect 110 Vac lamps to V1 and V2 circuit to allow observation of circuit energization:

V1 TB1-24 and TB1-25 V2 TB1-27 and TB1-28

Hook-up a jumper to the following terminals to simulate differential pressure switch (DP1):

TB1-20 TB1-21

Hook up a jumper to the following terminals to simulate remote emergency stop pushbutton (PB2) See Dwg. No. 593-6960501 Sheet 5:

TB3-9 TB3-10 and

TB3-11 TB3-12

Install jumper from TB1-11 - TB1-12. (Dwg. No. 6960501 Sheet 3)

Connect 440 Vac Power Leads.

Close circuit breaker, pull out EMERGENCY STOP pushbutton (PB1) and observe:

- After initializing, the Display Unit (DU1) momentarily displays program version numbers

Record DU1 Ver No. PDU _______

Record PLC Ver No. SWP _______

- Display Unit (DU1) then displays message "A) PRESS TIMED-START".

- Motor Current Meter (A1) should indicate in the green "MOTOR OFF" region.

- Verify with voltmeter 440 Vac at TXFMR primary H1 H4

Record measured voltage ________

- Verify with voltmeter 110 Vac at TXFMR secondary X1 X2

Record measured voltage ________

- POWER ON light (DS1, White) is lit.

Safety checks: Press EMERGENCY STOP pushbutton (PB1) and verify:

- The POWER ON light (DS1, White) remains lit. The DU1 display should indicate:

11) Reset PB1 ESTOP, push TIMED START.

- After safety check, reset EMERGENCY STOP (pull out pushbutton).

Press Display Unit (DU1) function key F7 "LAMP TEST" and observe on local status indicator while pressed:

- FEED light (DS2, Green) is lit.

- WAIT light (DS3, Amber) is lit.

- DON'T FEED light (DS4, Red) is lit.

Also, on the controller observe:

- Alarm Horn (H1) sounds.

- PLC slot 3 LEDs A3, A4, A5 and A6 are lit.

- Motor Current Meter A1 reads full scale.

- All segments of Display Unit (DU1) are lit.

Press Display Unit (DU1) function key F4 "HALT PULPER" and observe while pressed:

- Message Display Unit (DU1) should display F4) PULPER HALTED.

Press Display Unit (DU1) function key F5 "ADVANCE TIMERS" and observe while pressed:

- Message Display Unit (DU1) should display F5) TIMERS ADVANCED.

Press Display Unit (DU1) function key F6 "DISPLAY MOTOR CURRENT" and observe while pressed:

- Message Display Unit (DU1) should display

MOTOR I_in I_out PCT 0A 4mA 4mA 0%

Remove metal flag from proximity switch (PX1) to simulate the Access Door/Feed Chute being open, observe LED on PX2 is lit and LED on PX1 is out, the DON'T FEED light (DS4) is lit, and observe Message Display Unit says "05) DOOR/COVER OPEN or UNLATCHED."

Press the TIMED START pushbutton (PB3) to attempt to pick up the Master Control Relay (MCR).

Press Display Unit (DU1) function key F1 "JOG MOTOR ON" and observe while pressed:

- Motor Contactor (M1) should not operate.

- Message Display Unit (DU1) "99) F1 - F3 NOT ACTIVE WHEN SHUTDOWN."

Replace metal flag on Proximity Switch PX1, remove metal flag from Proximity Switch PX2 to simulate junkbox door/feed chute being open, observe LED on PX1 is lit and LED on PX2 is out, the DON'T FEED light (DS4) is lit, and observe Message Display Unit says "05) DOOR/COVER OPEN or UNLATCHED."

Press the TIMED START pushbutton (PB3) to attempt to pick up the Master Control Relay (MCR), and immediately press Display Unit (DU1) function key F4 "HALT PULPER" and observe Message Display Unit says "F4) PULPER HALTED." When released, Message Display Unit says "05) DOOR/COVER OPEN or UNLATCHED."

Press Display Unit (DU1) function key F1 "JOG MOTOR" and observe while pressed:

- Motor Contactor (M1) should not operate.

- Message Display Unit (DU1) "99) F1 - F3 NOT ACTIVE WHEN SHUTDOWN."

Replace metal flag on Proximity Switch PX2.

Press the TIMED START pushbutton (PB3) to pick up the Master Control Relay (MCR), and immediately press Display Unit (DU1) function key F4 "HALT PULPER" and observe Message Display Unit says "F4) PULPER HALTED." When released, Message Display Unit says "A) PRESS TIMED-START."

Press Display Unit (DU1) function key F1 "JOG MOTOR" and observe while pressed:

- Motor Contactor (M1) should operate.

- Message Display Unit (DU1) "F1) MOTOR JOG ON."

Press Display Unit (DU1) function key F2 "OPEN INLET VALVE" and observe while pressed:

- V1 is lit.

- Message Display Unit (DU1) should display F2) INLET VALVE V1 Forced OPEN.

Press Display Unit (DU1) function key F3 "OPEN EDUCTOR VALVE" and observe while pressed:

- V2 is lit.

- Message Display Unit (DU1) should display F3) EDUCTOR VALVE V2 Forced OPEN.

Timed Start Verification

- Display unit (DU1) displays message "A) PRESS TIMED-START."

Push TIMED START pushbutton (PB3) and observe:

- PLC slot 3 LEDs A7 and A8 are lit.

- 110 Vac lights are lit ... V1 and V2 from Step 5

- DON'T FEED light (DS4, Red) is lit

- Display Unit (DU1) displays message "B) FILLING, DON'T FEED 00:00" and displays the count down from 30 seconds.

After 30 seconds observe:

- DON'T FEED light (DS4, Red) goes off and FEED light (DS2, Green) is lit.

- Motor contactor (M1) also operates.

- Hour meter is operating.

- Display Unit (DU1) displays message "C) FEED, when done press TIMED-STOP".

Verify:

- That controller properly sequences to the FEED mode and remains stable in this mode (1 minute minimum).

- V1, V2 should remain on.

Timed Stop Verification:

Push the TIMED STOP pushbutton (PB4) and observe:

- Display Unit (DU1) displays message "D) CLEANING, DON'T FEED 00:00" and displays the count down from 15 minutes.

- FEED light (DS2, Green) is not lit and DON'T FEED light (DS4, Red) is lit.

Press Display Unit (DU1) function key F5 "ADVANCE TIMERS" and observe:

- While pressed, DU1 message is "F5 TIMERS ADVANCED"

- V1 light is not lit and V2 light remains lit

- Motor contactor (M1) drops out

- DON'T FEED light (DS4, Red) is lit

- Display Unit (DU1) displays message "E) DRAINING, DON'T FEED" and counts down from 60 seconds.

After 1 minute observe:

- V2 light is not lit

- DON'T FEED light (DS4, Red) is not lit

- Display Unit (DU1) displays message "A) PRESS TIMED-START."

Verify operation of current transducer XDCR1 and overcurrent alarms.

Remove 440 Vac Power.

Connect Vac current source through CT1 (use variac with 5 turns through CT1).

Install the clamp-on ammeter on one of the variac output leads.

Provide 440 Vac Power.

Press the TIMED START pushbutton (PB3) and allow pulper to sequence to FEED mode.

Adjust the variac output as follows and observe:

- Slowly increase variac so that the motor current meter (A1) is observed to deflect to the right and near the top of the green "normal operation" band.

- Press the display unit (DU1) function key F6 "DISPLAY MOTOR CURRENT" and record the observed readings.

MOTOR I_in I_out PCT

_______A _______mA _______mA _______%

- Also record the clamp-on ammeter current reading ______A.

- When pressing F6 the MOTOR current should read approximately 25A while the clamp-on ammeter reads 5A.

- Adjust the variac so that the motor current meter (A1) deflects further to the right and into the red "OVERCURRENT" region.

Deenergize variac by unplugging (Do not adjust knob from this setting).

Short time overload simulation:

- Reapply power to variac by plugging it in for no longer than 5 seconds to simulate a short time overload.

Observe during applied power to variac:

- WAIT light (DS3, Amber) is lit.

- Display Unit (DU1) displays message "01) HIGH CURRENT, WAIT 00:00" and counts down from 5 seconds.

After variac is unplugged and after 5 seconds has expired, observe:

- WAIT light (DS3, Amber) is not lit.

- FEED light (DS2, Green) is lit.

- Display Unit (DU1) displays message "C) FEED, when done press TIMED-STOP."

Long time overload simulation:

Reapply power to variac for longer than 5 seconds.

After 5 seconds, observe:

- WAIT light (DS3, Amber) is not lit

- DON'T FEED light (DS4, Red) is lit

- ALARM HORN (H1) sounds

- Display Unit (DU1) displays message "02) OVERCURRENT, DON'T FEED 00:00" and maintains a countdown time of 00:60.

Press ALARM ACKNOWLEDGE (PB5) to silence alarm. Allow controller to operate in this mode for several minutes. Observe:

- Alarm should not sound again and DON'T FEED light (DS4, Red) should remain lit.

Long time overload restore simulation:

Unplug the variac.

Observe:

- DON'T FEED light (DS4, Red) should remain lit for 1 minute.

- Display Unit (DU1) displays message "02) OVERCURRENT, DON'T FEED 00:00" and counts down from 60 seconds.

After 1 minute observe:

- DON'T FEED light (DS4, Red) is not lit, FEED light (DS2, Green) is lit

- Controller should now be back to the FEED mode.

- Display Unit (DU1) displays message "C) FEED, when done press TIMED-STOP."

Differential pressure (DP1) circuit verification:

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Remove the jumper from TB1-20 TB1-21.

After 5 seconds, observe:

- Motor contactor (M1) drops out

- V1 and V2 lights go out

- DON'T FEED light (DS4, Red) is lit

- Display Unit (DU1) displays message "04) LOW WATER FLOW, Correct & Restart."

Proximity sensor verification:

Reset DP1 by hooking up the jumper from TB1-20 TB1-21.

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Remove metal flag from proximity switch PX1.

Observe:

- Motor contactor (M1) drops out

- V1 and V2 lights go out

- DON'T FEED light (DS4, Red) is lit.

- Display Unit (DU1) displays message "05) DOOR/COVER OPEN or UNLATCHED."

- Replace metal flag on PX1.

Allow controller to sequence to the FEED mode by pressing the TIMED START PUSHBUTTON.

Remove metal flag from proximity switch (PX2).

Observe:

- Motor contactor (M1) drops out

- V1 and V2 lights go out

- DON'T FEED light (DS4, Red) is lit.

- Display Unit (DU1) displays message "05) DOOR/COVER OPEN or UNLATCHED."

- Replace metal flag on PX2.

E-Stop Circuit Verification:

a) Controller E-STOP (PB1)

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Push in E-Stop PB1.

Observe:

- Controller should shut down. The POWER ON light (DS1, White) should remain lit.

- The Display Unit (DU1) should display:

11) Reset PB1 ESTOP, push TIMED START

Reset E-Stop (PB1).

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

b) Pulper remote E-Stop (PB2) (if pulper not connected)

Simulate remote E-Stop switch being pushed in by removing jumper TB3-9 TB3-10.

Observe:

- Controller should shut down. The POWER ON light (DS1, White) should remain lit.

- The Display Unit (DU1) should display:

08) RMT ESTOP pushed, press TIMED START

- Replace jumper TB3-9 TB3-10.

- Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Conductivity Sensor Circuit Verification:

Allow controller to sequence to FEED mode by pressing the TIMED START PUSHBUTTON.

Install jumper across CONDUCTIVITY SENSOR circuit

TB1-17 TB1-18

Observe:

- Controller should shut down after 2.0 seconds.

- Motor contactor (M1) drops out.

- V1 and V2 lights go out.

- DON'T FEED light (DS4, Red) is lit.

- Display Unit (DU1) displays message "03) HIGH WATER LEVEL."

Remove jumper TB1-17 TB1-18.

Solenoid Fuse Blown Simulation:

Press the EMERGENCY STOP PUSHBUTTON (PB1).

Remove fuse F5 from the fuse holder.

Pull out the EMERGENCY STOP PUSHBUTTON (PB1):

- After the message display (DU1) initializes, the display message should be:

10) FUSE F5 BLOWN.

- Press the EMERGENCY STOP PUSHBUTTON (PB1).

- Replace Fuse F5.

OverLoad Tripped Simulation:

- Press the TEST BUTTON on the overload relay.

- Display Unit (DU1) displays message "12) MOTOR OVERLOAD TRIPPED.”

- Reset the overload by pressing the RESET BUTTON

Current Sensor Failure Simulation:

- Depress the EMERGENCY STOP PUSHBUTTON (PB1).

- Remove the lead from the CURRENT TRANSDUCER (XDCR1), Terminal 6.

- Tape the ring terminal to insulate.

- Pull out the EMERGENCY STOP PUSHBUTTON (PB1).

- Display Unit (DU1) displays message "6) CURRENT SENSOR FAILED”

- The motor current meter should be indicating in the red “SENSOR FAILED” region.

- Depress the EMERGENCY STOP PUSHBUTTON (PB1).

- Remove the tape and reconnect the ring terminal that was removed from the CURRENT TRANSDUCER (XDCR1), Terminal 6.

- Pull out the EMERGENCY STOP PUSHBUTTON (PB1).

- Display Unit (DU1) displays message "A) PRESS TIMED START.”

Disconnect 440 Vac power leads, variac leads, 110 Vac lamps

(V1 TB1-24 to TB1-25, and V2 TB2-27 to TB2-28), differential pressure switch jumper (TB2-20 to TB2-21), local status indicator jumpers (TB3-9 to TB3-10, and TB3-11 to TB3-12), proximity switches on TB3.

The pulper select jumper TB1-11 to TB1-12 should remain in control enclosure.

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File details come from the government source that posted it. Updated Jun 29, 2023.